Investigation of process characteristics of dry machining and quality of the machined surface in hard turning

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Details of project

Identifier

42962

Type

Principal investigator

Kundrák, János

Title in Hungarian

A szárazmegmunkálás folyamatjellemzőinek és a megmunkált felület minőségének vizsgálata keményesztergálásnál

Title in English

Investigation of process characteristics of dry machining and quality of the machined surface in hard turning

Panel

Engineering, Metallurgy, Architecture and Transport Sciences

Department or equivalent

Gyártástudományi Intézet (University of Miskolc)

Participants

Bana, Viktória
Gyáni, Károly
Szabó, Sándor
Tolvaj, Béla

Starting date

2003-01-01

Closing date

2006-12-31

Funding (in million HUF)

9.450

FTE (full time equivalent)

0.00

state

closed project

Final report

Results in Hungarian

Megállapítottuk, hogy a hűtés-kenés elmaradása megnövelve a munkadarab és a szerszám hőterhelését, változásokat okoz a keményesztergálás folyamatjellemzőiben. Ezért megvizsgáltuk a hőtani jellemzőket, a forgácsolóerő , a forgácsdeformáció és a szerszámkopás jellegzetességeit. A munkadarabon a változásokat a geometriai jellemzők, a felületi érdesség és a felszíni réteg többirányú vizsgálata alapján mutattuk be. Végesdifferencia módszerrel elvégeztük a jellegzetesfelületek hőmérséklet terének numerikus vizsgálatát. A hőmérséklettér meghatározására és vizualizálására a FLUENT végestérfogatok szoftvert is alkalmaztuk Meghatároztuk azon tervezési elveket, amelyekkel a precíziós megmunkálásokra előírt méret- és alakpontosság keményesztergálással ugyanúgy elérhető, mint köszörüléssel. 3D érdességi paraméterek segítségével meghatároztuk keményesztergálásra azokat a technológiai feltételeket, amelyekkel azonos vagy jobb felület állítható elő, mint köszörüléssel. Összehasonlító vizsgálatokkal megállapítottuk, hogy keményesztergált felületek felszín alatti rétege élettartam szempontjából kedvezőbb, mint a köszörültté. Meghatároztuk azokat a forgácsolási feltételeket és összefüggéseket, amelyek segítségével a működés szempontjából kedvezőtlen fehér réteg megjelenése elkerülhető. Módszert dolgoztunk ki, mellyel az alkatrészrajzon előírt érdességi jellemző megengedett értékének figyelembevételével határozható meg a forgácsoló-szerszám megengedett kopása. Kritérium-rendszert és döntési algoritmust dolgoztunk ki a befejező megmunkálási eljárások célszerű megválasztásához.

Results in English

We have stated that the omission of cooling and lubricating increases the heat load of the workpiece and it leads to changes in the process characteristics of hard turning. That is why we examined the heat characteristics, the cutting strength, the chip deformation and the wear of the tool. On the basis of geometrical characteristics, surface roughness and a multi direction examination of the surface layer, we introduced the changes on a workpiece. With the method of finite difference we carried out the numerical examination of the typical surfaces' temperature area. For the determination and visualisation of temperature area we applied FLUENT finite volumes software. We defined the design principles with which the prescribed for precision machining size and form accuracy can be reached just like with grinding. With the help of 3D roughness parameters we defined the technological parameters for hard turning, with which the same or better surface can be reached than in grinding. We stated that from the point of view of lifetime, the under surface layer of the hard turned surfaces is more advantageous than that of the ground ones. We determined the cutting conditions and relationships with the help of which the emerge of the white layer - which is not advantageous for the process - can be avoided. We elaborated a method with which the allowed wear of the cutting tool can be defined taking the roughness characteristic prescribed in the part drawing into consideration. To be able to choose purposefully among the finish machining processes, we elaborated a criterion system and a decision algorithm.

Full text

http://real.mtak.hu/860/

Decision

Yes

List of publications

Kundrák J., Keserű P.: Modelling of out-of-roundness with finite element method in hard turning, Cutting and tool in manufacturing systems (megjelenés alatt), 2006

Kundrak J., Karpuschewski B., Bana V., Gyani K.:: Accuracy of hard turning, Journal of Materials Processing Technology (közlésre leadva), 2007

Kundrak J., Bana V., Gyani K.:: Roghness of ground and hard turned surfaces on the basis of 3D parameters, International Journal of Advanced Manufacturing Technology. (közlésre leadva), 2007

Kundrak J.: Alternative Machining Procedures for Finishing of Hardened Steels, Proc. on the 1st Jubilee Scientific Conf. MANUF. ENG. IN TIME OF INF. SOCIETY Gdans, 1-2 June, 2006, pp.: 215-224 (ISBN 83-88579-61-4), 2006

Kundrák J., Bana V.: Surface integrity of hardened bores, Proc. on the microCAD´2005 International Scientific Conference, Section M: Production Engineering and Manufacturing Systems Miskolc, Hungary 10-11 March 2005 pp.89-96, 2005

Kundrák J., Tóth T., Gyáni K.: How to make a choice of machining methods on the basis of economy: comparison between hard turning and grinding, In: Proceedings of the 11. International Conference on Machine Design and Production (UMTIK 2004), Antalya, pp.:31-45., 2004

Mamalis A.G., Kundrák J., Horvath M.: On a novel tool life relation for precision cutting tools, Journal of Manufacturing science andengineering-transactions of the asme 127(2):328-332 May 2005, 2005

Sukaylo V.A., Kaldos A., Krukovsky G.: Development and verification of a computer model for thermal distortions in hard turning, Journal of Materials Processing, 2005

Kundrak J., Bana V.: Model for cutting forces in hard turning of bores, In: Annals of DAAAM & Proceedings of the 15th International DAAAM Symposium,Vienna, pp.:241-242, 2004

Kundrák J., Bana V.: Surface profile and roughness after hard machining, In: Proceedings of Scientific-Technical Conference Metrology 2003., Krakkow, 2003

Kundrák J., Bana V.: Microgeometry of bore-holes after hard machining, In: Proceeding of the International Conference on Trends and Development of Machinery and Associated Technology (TMT), Lloret de Mar, Barcelona, pp. 93-96, 2003

Kundrák J., Bana V.: Study on the surface layer in hard cutting, In: Annals of DAAAM & Proceedings of the14th International DAAAM Symposium,Sarajevo, pp. 251-252, 2003

Berta M., Cser I.: Questions of Operation Planning of Machining Carried out on Turning Centres, In: 2nd International Conference of ''Research and Education'' , Miskolc, pp.:19-25, 2004

Kundrák J., Bana V.: Study of Surface Roughness in Precision Machining, In:2nd International Conference of „Research and Education” Miskolc: 2004 pp.95-102, 2004

Kundrák J: Method for defining the permissible wear of cutting tools in finishing machining, Rezanie i Instrument v technologicheskikh sistemakh No.66,pp.: 68-72, 2004

Kundrak J., Bana V.: Geometrical Accuracy of Hard Cut Parts, In: 8th International Research/Expert Conference /Trends in the Development of Machinery and Associated Technology/TMT 2004, Neum, pp.:255-258., 2004

Kundrák J., Bana V.: Geometrical accuracy of machining of hardened bore holes, In: WESIC 2003 4th Workshop on European Scientific and Industrial Collaboration, Miskolc, pp.: 473-480., 2003

Kundrák J., Bana V.: State of the surface layer after hard turning, Cutting and tool in manufacturing systems No64, pp. 110-118, 2003, 2003

Kundrák J.: Advantages of hard cutting in machining of hardened bores, In: Proceeding of the International Congress of Precision Machining (ICPM), 2003, Prague, pp. 180-186., 2003

Kundrák J.: Hard Boring, In: Proceedings of the International Scientific Yearly Symposium „UNIVERSITARIA ROPET 2003”, Petrosani, pp. 311-316., 2003

Kundrák J.: Tool-life in finishing machining, In: Proceedings of the 6th International Conference Modern Technologies in Manufacturing , Cluj-Napoca, pp. 275-278, 2003

Kundrák J., Gyáni K.: Szuperkemény szerszámokkal végzett precíziós megmunkálások kutatása, Gépgyártás, XLVI. évfolyam, 3 . szám, pp.: 3-9., 2006

Bana V., Karpuschewski B., Kundrak J., Hoogstrate A.M.: Thermal distortions in the machining of small bores,, JMPT-Juournal of Materials Processing Technology (közlésre leadva), 2007

Mamalis A.G., Kudrak J., Gyani K.: Environmentally friendly precision machining, Material Manufacturing Processes 21 (1):29-37, 2006

Kundrák J., Bana V.: Some Questions About Quality Assurance Of Precision Parts With Hardened Surface, Cutting and tool in manufacturing systems No.69, pp.121-128, (ISSN 0370-808X)., 2005

Kundrák J: Effectiveness of alternative machining processes in precision machining, Cutting and tool in manufacturing systems No.68,pp.281-289,(ISSN 0370-808), 2005

Kundrák J., Gyáni K., Bana V.: Qualification of hard bored surfaces with 3D parameters, DAAAM Scientific Book , Vienna 2005, pp. 371-384, 2005

Mamalis A.G., Kundrák J., Manolakos D.E., Markopoulos A.,: Finite Element Modelling of Hard Cutting, Proc. on the microCAD´2005 International Scientific Conference, Section M: Production Engineering and Manufacturing Systems Miskolc , Hungary 10-11 March 2005 pp.113-118, 2005

Kundrák J.: Cutting of hardened steels (In Hungarian), XIII. Nemzetközi Gépész Találkozó (13th International Conference in Mechanical Eng.) Szatmárnémeti, 2005. ápr. 28–máj.1 (Satu Mare, April 28-May 1, 2005),pp.213-218, 2005

Kundrák J., Bana V.: Modelling of geometrical accuracy in machining of hardened steels, . Proceedings of the 6th Int. Conf. on Computer-Aided Industrial Design&Conceptual Design, Delft, the Netherlands, May29-June1 2005 pp.: 470-475 (ISBN 7-5062-7444-2), 2005

Kundrák J., Gyáni K., Bana V.: Why is hard turning more economical than grinding in machining of disc type parts?, . ITC 2005 4th International Tools Conference, May 24-25, 2005, Zlin, Czech Republik, in CD (ITC2005_4) p. 14 (ISBN 80-7318-305-6), 2005

Kundrák J., Gyáni K., Bana V.: 3D topography of hard turned and ground surfaces, 3rd International Congress of Precision Machining 2005, October 18-19, 2005, Vienna Austria p.195-202., 2005

Kundrák J., Gyáni K., Bana V.: Accuracy of hard boring, The 5th International Scientific Conference DEVELOPMENT OF METAL CUTTING, Kosice 12.-13.9.2005 pp:H5-H10, 2005

Kundrák J., Gyáni K., Bana V.: Comparison of accuracy of hard turned and ground bores, 3rd International Conference on Computer Aided Design and Manufacturing, September 27th-October 1st 2005. Supetar –Croatia, Book of Abstracts, p.41-42, 2005

Kundrák J., Gyáni K., Emmer T.: Grading of the roughness of hard turned external cylindrical surfaces on the base of 3D roughness examinations, High Technologies of machine-buildig, Printed scientific works NTU “KhPI” 2’2005, pp:219-230., 2005

Kundrák J., Emmer T., Szatmári Z.: Cutting forces in hard turning of shafts (In German), Proc. on the microCAD´2005 International Scientific Conference, Section M: Production Engineering and Manufacturing Systems Miskolc , Hungary 10-11 March 2005 pp.81-87, 2005

Kundrák J: Applicability of hard cutting for machining of hardened bore-holes, In: Proceedings of the Fifth International Symposium on Tools and Methods of Competitive Engineering (TMCE 2004), Lausanne, pp.:649-660, 2004

Kundrák J: Research and Development in Hard Cutting, In:2nd International Conference of „Research and Education” Miskolc: 2004 pp.95-102, 2004

Tóth T., Kundrák J., Gyáni K.: The material removal rate and the surface rate as two new parameters of qualification for hard turning and grinding, In: Proceedings of the Fifth International Symposium on Tools and Methods of Competitive Engineering (TMCE 2004), Lausanne, pp.:629-639, 2004

Kundark J., Mamalis A.G., Gyani K., Markopoulos A.: Environmentally friendly precision machining, ''közlésre elfogadva'' Materials and Manufacturing Processes, 2004

Mamalis A.G., Kundrak J., Manolakos D.E.: Effect of the workpiece material on the heat affected zones during grinding: a numerical simulation, International Journal of Advenced Manufacturing Technology 22(11-12): 761-767 dec 2003, 2003

Mamalis A.G., Kundrak J., Gyani K.: On the surface integrity of precision-ground steel cylindrical parts, Materials and Manufacturing Processes 18(5): 835-845 2003, 2003

Mamalis A.G., Kundrak J., Gyani K.: On the dry machining of steel surfaces using superhard tools, International Journal of Advenced Manufacturing Technology 19(3): 157-162 2002, 2002

Sukaylo V.A., Krukovsky P., Kaldos A., Kundrák J., Bana V.:: Computer-based modelling of thermal distortions in turning, Proceedings of the Institution of Mechanical Engineers Part B-Journal of Engineering Manufacture 217(3): 363-371 2003, 2003

Mamalis A.G., Kundrak J., Horvath M.: Wear and tool life of CBN cutting tools, International Journal of Advenced Manufacturing Technology 20(7): 475-479 2002, 2002

Mamalis A.G., Kundrak J., Manolakos D.E.: Thermal modelling of surface grinding using implicit finite element techniques, International Journal of Advenced Manufacturing Technology 21(12): 929-934 sept 2003, 2003

Kundrak J., Mamalis A.G., Markopolus A.: Finishing of hardened boreholes: Grinding or hard cutting?, Materials and Manufacturing Processes 19(6):979-993 2004, 2004

Kundrak J.: Effectiveness of Alternative Machining Process of Hardened Steel, Production Process in Mechanical Engineering - Research Reports, pp. 121-132, Cracow-Kosice, ISBN 80-8073-568-9, 2006

Afjehi-Sadat A., P. Osanna P.H., Kundrak J, Bana V.:: Evaulation of 3D surface topography of hard turned and ground gears’ bore holes, Research Reports, pp. 141-146, Cracow-Kosice, ISBN 80-8073-568-9, 2006

Kundrák J., Grabchenko A. I., Zubar V.P.:: Cutting of internal surfaces with CBN tools (In Russian), Sovremennye technologiii v mashinostroenii ( 1.kötet, 147-156 Advence technologies in production engeneering vol.:I, pp. 147-156, 2006

Kundrak J.: Surface roughness – as a criterion of tool-life Sovremennye technologiii v mashinostroenii, 11. kötet, Advence technologies in production engeneering vol.: II, pp. 371-379, 2006

Ali Afjehi-Sadat, Janos Kundrak, P. Herbert Osanna, Viktoria Bana:: Investigation of 3D topography of surface measurement after hard turning and grinding, Proc. on the microCAD´2006 International Scientific Conference, Section M: Production Engineering and Manufacturing Systems, Miskolc , Hungary 16-17 March2006 pp.211-218, 2006

R. Tóth, J. Kundrák: Basics of CFD heat dynamics modelling for hard turning, Proc. on the microCAD´2006 International Scientific Conference, Section M: Production Engineering and Manufacturing Systems, Miskolc , Hungary 16-17 March2006 pp.163-168, 2006

Kundrák J., Tomolya K., Sólyom J, Gácsi Z., Bana V.:: Surface Investigation of Gear Machining by Hard Cutting (in Hungarian), Proc. on the microCAD´2006 Intern. Scientific Conf., Section D: Material Science, Miskolc , Hungary 16-17 March 2006 pp.61-68 (ISBN 963 661 700 7 Ö, ISBN 963 661 704 X), 2006

Kundrak J.: Defining of Tool Life on the Basis of Roughness Limit (In hungarian), 14th International Conference in Mechanical Engineering, Tg. Mures, April 27-30, 2006 . pp.:226-ISBN (10) 973-7840-10-0; ISBN (13) 978, 2006

Bana V., Karpuschewski B., Kundrak J., Hoogstrate A.M.: Thermal distortions in the machining of small bores, Proceedings of AMPT 2006, July 30-Aug 3, 2006, Las Vegas, USA, in CD p. 4., 2006

Kundrak J., Osanna P.H., Afjehi-Sadat A., Bana V.:: Surface Quality of hard turned Bore Holes, XVIII IMEKO World Congress - Metrology for a Sustailable Development, Rio de Janeiro, Brazil, 17-22 September 2006, 2006

Kundrak J., Gyani K., Bana V. , Deszpoth I.:: Algorithm for hard turning of disc type parts, 5th INTERNATIONAL TOOLS CONFERENCE ITC 2006 September 5 - 6, 2006, Zlín, Czech Republic, in CD p.13. ( ISBN 80-7318-448-6), 2006

Bana V.:: Manufacturing of high precision bores ISBN-10: 90-9020708-2; ISBN-13: 978-90-9020708-7, Technische Universiteit Delft, 2006

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